I guess pellet stoves are neither designed for corn, but it just works.Wondering when you'd chime in.... I have 7 ton of bagged corn in the barn and 3 ton of pellets but I'm too lazy to mix any up right now....lol Besides, the thermostat on the propane furnace is much easier to deal with...lol
Animal stomach is natural's grinder. I would feed the corn to a few cattle along with hay and pelletize dried cow dung for burning.
I believe the small extruders don't press materials as hard as commercial pellet mills, but we can figure out some adhesive additive to make better glued together pellets. What's your extruder's normal operating temperature? Can we heat the raw material to 400 deg F?
If you have a source of waste HDPE, PP or PET maybe grind them down and mix 5% by weight into biomass stream, because these resins would enhance cold strength and rigidity of the resulting pellet.